| The tubular parts have been widely used in auto industry. There are two main traditional methods for manufacturing tubular parts; one is welded by the tube with different diameters after bending process. The other is pressed into a half-slab-shaped groove into a closed section of the weld. Both processe require more manufacturing process, tooling equipment, with low productivity. The parts are weighted. The production is too poor and also the parts are low intensity. With the necessary to meet the technical requirements of lightweight in the auto industry, it is urgent for new production technology to improvement the manufacturing process. Tube Hydroforming technology is just able to resolve the shortcomings of traditional technology. Tube hydroforming technology not only for providing a new way of thinking, but also to reduce the welding and assembly processes, reduce component weight, reduce the number of parts, improve integrity and strong component weight ratio, down low production time, also the production costs .but it can achieve better performance and lightweight . It is booming with the future development of the automobile industry.With the booming development of China's auto industry, the domestic auto OEMs and suppliers have pay attention to the tube hydroforming technology in recent years. However to develop tube hydroforming process, there are many facts to think about .Such as the raw materials with high-performance, tube pre-forming process. special tube manufacturing process, high-pressure hydraulic press line , tube forming process in the mold manufacturing and the lubrication in process is also important,. In many parts also need to punch holes in their bodies, if without punching die, laser punching and other equipment is necessary. All in all, building a tube hydroforming production line should take many factors into account. Before making investment on the products, the part supplier needs to conduct detailed analysis. First, the tube hydroforming technology principle is introduced, its application in the development of industry and other factors are described. Tube hydroforming based on the relevant theory of the instrument support beams to simulate the forming process with the simple linear load line from 0MPa -50MPa. With a preliminary free bulging process analysis on instrument support beams, getting a three bulging intervals, and according to numerical simulation results we can obtain the feeding and break situation it may be encountered in the actual production. Through tube bulging process by analyzing the deformation behavior and defects, we can get a more detailed route for internal pressure. Tube forming process was developed and makes simulation research. Initial development of the two forming process.1. By internal pressure and axial feeding matching together, the breakdown of instrument support is feed and the broken phenomenon is eliminated in the process.2. Two-step bulging process is designed on the instrument support beam. The axial hydroforming process and radial bulging process method.By comparison the results numerical simulation of the above processe, process 1 is not able to achieve the objective and make complete elimination of rupture. But the rupture phenomenon can completely eliminated in process 2 which along the radial hydrforming process.Base on the above process, get the max thinning site in this part, make the aim should be achieved in the tube bending process development which bending tube must meet. With this to select tube bending process also based on the principle of economy, and the bending progressment of instrument beams were analyzed.In order to better the bended tube in bulging process, also confirm the quality of bended tube in hydroforming process in a more reasonable load path which can confirm the pre-forming process correct or not and the feasibility of the loading paths. Finally, the bulging quality in annealing process of bending tube was analyzed, for getting more solutions in the actual process.
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